12.15 Reference Number: Title: Lead Acid Battery Manufacture

437 Pages·2006·10.52 MB·English

AP-42 Section Number: 12.15
Reference Number:
-
Title: Lead Acid Battery Manufacture
Background Information for Proposed
Standards
EPA 45013-79-028a
US EPA
November 1979
c
..
TABLE OF CONTENTS (continued)
Page
4.0 EMISSION CONTROL TECHNIQUES 4-1
4.1 Grid Casting Machines and Furnaces 4-2
4.2 Paste Mixer 4-9
4.3 Three-Process Operation (Stacking, Burning,
and Assembly) 4-17
4.4 Lead Oxide Production 4-24
4.5 Lead Reclamation 4-27
4.6 Formation 4-32
4.7 Control Performance Summary 4-38
5.0 MODIFICATIONS AND RECONSTRUCTION 5-1
5.1 General 5-1
5.2 Applicability of 40 CFR 60.14 and 60.15 to
the Lead-Acid Battery Manufacturing Industry 5-4
5.3 Illustrative Examples 5-9
6.0 EMISSION CONTROL SYSTEMS 6-1
6.1 Application of Control Techniques 6-2
6.2 Selected Control Alternatives 6-2
6.3 Effectiveness of Selected Lead Emissions
Control Systems 6-5
7.0 ENVIRONMENTAL IMPACT 7-1
7.1 Air Pollution Impact 7-1
7.2 Water Pollution Impact 7-10
TABLE OF CONTENTS (continued)
7-1 1
7.3 Solid Waste Impact
7.4 Energy Impacts 7-20
7-24
7.5 Other Environmental Impacts
7-24
7.6 Other Environmental Concerns
8.0 ECONOMIC IMPACTS 8-1
8.1 Industry Economic Profile 8-1
8.2 Cost Analysis of Alternative Control Systems 8-12
8!3 Other Cost Considerations 8-72
8.4 Economic Impact of Control Alternatives 8-85
9.0 RATIONALE FOR THE PROPOSED STANDARDS 9-1
9.1 Selection of Source for Control 9-1
9.2 Selection of Pollutants and Affected
Facilities 9-1
9.3 Selection of Best System of Emission
Reduction Considering Costs 9-6
9.4 Selection of the Format of the Proposed
Standard 9-11
9.5 Selection of Emission Limits 9-15
9.6 Opacity Standards 9-21
9.7 Modification/Reconstruction Considerations 9-23
9.8 Selection of Monitoring Requirements 9-23
9.9 Selection of Performance Test Methods 9-24
V i
TABLE OF CONTENTS (continued)
APPENDIX A EVOLUTION OF THE SELECTION OF THE BEST
SYSTEM OF EMISSION REDUCTION A-1
APPENDIX B INDEX TO ENVIRONMENTAL IMPACT
CONSIDERATIONS B-1
APPENDIX B INDEX TO ENVIRONMENTAL IMPACT
CONSIDERATIONS B-1
APPENDIX C SUMMARY OF TEST DATA c-1
APPENDIX D EMISSION MEASUREMENT AND CONTINUOUS
MONITORING D-1
APPENDIX E ENFORCEMENT ASPECTS E-1
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LIST OF FIGURES
No. Page
3-1 Trends in Lead-Acid Battery Shipments and in Gross 3-3
National Product
3-2 United States Shipment of SLI Lead-Acid Batteries 3-7
from 1947 to 1974
3-3 A Lead-Acid Storage Battery 3-10
3-4 Components of a Battery Element 3-1 1
3-5 Process Flow Diagram Showing Uncontrolled Lead 3-13
Emission Factors for Lead-Acid Battery Manufacture
4-1 Particle Size of Particulate Emissions from a Grid 4-3
Casting Operation
4-2 Uncontrolled Grid Casting Emissions 4-5
4-3 Controlled Emissions from Plant D Roto-Clone 4-6
Controlling Grid Casting and Mixer Emissions
4-4 Graphic Representation of Emissions Vented to Plant D 4-7
Roto-Clone Over a Period of Time
4-5 Particle Size of Particulate Emissions From a Paste 4-1 1
Mixer
4-6 Uncontrolled Paste Mixing Emissions 4-1 5
4-7 Controlled Paste Mixing Emissions 4-1 6
4-8 Particle Size of Particulate Emissions From a Three- 4-19
Process Operation
4-9 Particle Size of Particulate Emissions From a Three- 4-20
Process Operation
4-10 Uncontrolled Three-Process-Operation Lead Emissions 4-21
4-11 Controlled Three-Process-Operation Lead Emissions 4-22
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LIST OF FIGURES (continued)
N-o. Page
4-12 Emissions from Ball Mill Lead Oxide Production 4-26
Using a Baghouse for Product Recovery (gr/dscf)
4-13 Particle Size of Particulate Emissions From a Lead 4-28
Reclaim Furnace
4-14 Uncontrolled Lead Emissions Exhaust to Spray Tower 4- 30
!
Controlling Lead Reclaim Emissions
, .. 4-15 Controlled Lead Emissions from Spray Tower 4-31
Controlling Lead Reclaim Emissions
4-16 Average Uncontrolled Lead Emissions from Tested 4-36
Facilities
4-17 Average Controlled Lead Emissions from Tested 4-37
Facilities
4-18 Average Uncontrolled Lead Emissions from Tested 4- 39
Facilities
4-19 Average Controlled Lead Emissions from Tested 4-40
Facilities
5-1 Method of Determining Whether Changes to Existing 5-2
Facility Constitute a Modification or Reconstruction
Under 40 CFR 60.14 and 60.15
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7-1 Maximum Ambient Impact 1-h Maximum 7-3
7-2 Maximum Ambient Impact of Lead-Acid Battery 7-4
Manufacturing Plants for Various Plant Production
-
Rates 24-h Maximum
7-3 Maximum Ambient Impact of Lead-Acid Battery 7-5
Manufacturing Plants for Various Plant Production
-
Rates Annual mean
8-1 Regional Distribution of Lead-Acid Battery Plants 8-6
8-2 Reported Installed Costs of Fabric Filter Control 8-24
Systems Compared with Estimated Cost Curves Used
in this Study (4th Quarter 1977 Dollars)
i x
LIST OF FIGURES (continued)
No. Page
8-3 Reported Installed Costs of Wet Scrubber Systems 8-25
Compared with Estimated Cost Curves Used in this
Study
0-4 Cost-Effectiveness of Model Plant Control 8-70
Alternatives
C-1 Production Flow Diagram, Plant B c-2
C-2 Production Flow Diagram, Plant D C-8
C-3 Production Flow Diagram, Plant G C-14
LIST OF TABLES
-No. Q
3-1 United States Consumption of Lead (in Gigagrams) 3-4
3-1A United States Consumption of Lead (in Short Tons) 3-5
3-2 Summary of SLI Battery Use: 1974 3-6
3-3 Nationwide Emissions of Lead from the Manufacture 3-14
of Lead-Acid Storage Batteries (1975)
3-4 Typical Formulas for Positive and Negative Battery Pastes 3-17
4-1 Characteristics of Control Devices Tested 4-41
5-1 Annual Asset Guideline Repair Allowance Percentages for 5-4
Specified Facilities per IRS Publication 534 (1975 Edition)
5-2 F.O.B. Price of Various Components for Lead-Acid Battery 5-5
Manufacturing Facilities
6-1 Summary of Control Systems Applicable to Lead-Acid Battery 6-3
-
Manufacturing Facilities
6-2 Selected Control Alternatives for Lead-Acid Battery 6-4
Manufacturing Industry
6-3 Uncontrolled Emissions of Lead from Lead-Acid Battery 6-6
Manufacturing Facilities
6-4 Estimated Lead Collection Efficiencies of Selected Control 6-7
Systems
6-5 Effect of Control Alternatives of Lead Emissions from 6-8
Various Sized Battery Manufacturing Plants
6-5A Effect of Control Alternatives of Lead Emissions from 6-9
Various Sized Battery Manufacturing Plants (English Units)
6-6 Effect of Control Alternatives on Lead Emissions Compared 6-1 0
with SIP Controls
6-6A Effect of Control Alternatives on Lead Emissions Compared 6-11
with SIP Controls (English Units)
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L 1
1
LIST OF TABLES (continued)
&
-No.
7-1 Approximate Lead Emission Rates and Maximum Resultant 7-6
Ground-Level Lead Concentration for Two Plant Sizes
7-2 Allowable Ambient A i r Concentrations of Sulfuric-Acid 7-9
Mist
7-3 Lead Content of Scrubber Blowdown and Effect on Wastewater 7-12
System of a 6500-BPD Plant (Metric Units)
7-3A Lead Content of Scrubber Blowdown and Effects on Wastewater 7-1 3
System of a 6500-BPD Plant (English Units)
7-4 Sources, Quantities, and Disposition o f Waste Materials 7-14
(Metric Units) 1
7-4A Sources, Quantit ies and Disposition of Waste Materials 7-1 5
(English Units)
7-5 Estimated Daily Process Solid Wastes Generated at Lead-Acid 7-18
Battery Manufacturing Facilities
7-6 Potential Solid Waste Impacts of a Battery Plant Using 7-20
Control A1 ternative I
7-7 Energy Requirements for Lead-Acid Battery Manufacturing 7-22
Plants and Emission Control Equipment (Metric Units)
7-7A Total Energy Requirements for Lead-Acid Battery 7-23
Manufacturing Plants and Emission Control Equipment
(English Units)
8-1 Consumption of Lead in the United States by Product 8-2
8-2 Leading Domestic Storage Battery Manufacturers 8-3
8-3 Battery Shipments by Domestic Producers 8-8
-
8-4 Replacement Battery Shipments Automobiles 8-9
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LIST OF TABLES (continued)
N-o. Page
8-6 Selected Control Alternatives for Lead-Acid Battery 8-13
Manufacturing Industry
8-7 Typical Uncontrolled Exhaust Parameters for Battery 8-14
Manufacturing Facilities (Metric Units)
8-7A Typical Uncontrolled Exhaust Parameters for Battery 8-15
Manufacturing Facilities (English Units)
8-8 Uncontrolled Lead Emissions from Various Lead-Acid 8-16
Battery Manufacturing Facilities
8-9 Air Pollution Control Equipment Costs for Lead-Acid 8-19
Battery Manufacturing Facilities (Metric Units)
8-9A Air Pollution Control Equipment Costs for Lead-Acid 8-20
Battery Manufacturing Facilities (English Units)
8-10 Component Capital Cost Factors for a Fabric Filter 8-22
as a Function of Equipment Cost, Q
8-11 Component Capital Cost Factors for a Wet Collector 8-23
(Scrubber or Mist Eliminator) as a Function of
Equipment Cost, Q
8-12 Items Used in Computing Total Annualized Costs 8-2 7
8-13 Calculation of Annualized Costs of Air Pollution
Control Systems 6-28
8-14 Utilities and Labor Required for Operation of Various 8-30
Control Devices for Lead-Acid Battery Manufacturing
Facilities (Metric Units)
8-14 Utilities and Labor Required for Operation of Various 8-31
A Control Devices for Lead-Acid Battery Manufacturing
Facilities (English Units)
8-15 cost of Emission Control systems for Control 8-36
Alternative I for New Plants
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